Wheel manufacture



March 7, 1967 v D. H. BROOKS, JR., ETAL 3,307,388

- WHEEL MANUFACTURE 2 Sheets-Sheet 1 F IG.2

INVENTORS DEWEY H. BROOKS JR. ORVILLE W. JACOBS BY w 1% THEIR. ATTORNE Original Filed Jan. 16, 1961 Mar h 7,196 D. H. BROOKS, JR., ETAL 3,307,388

WHEEL MANUFACTURE 2 Sheets-Sheet 2 Original Filed Jan. 16, 1961 INVENTQRS DEWEY H.BROOKS JR. ORVILLE W. JACOBS FIGJO ST Q BY E 'MQ- z THEIR ATTORNEY United States Patent 3,307,388 WHEEL MANUFACTURE Dewey H. Brooks, Jr. and Orville W. Jacobs, Dayton, Ohio, assignors to The Sheffield Corporation, Dayton, Ohio, a corporation of Delaware Original application Jan. 16, 1961, Ser. No. 82,748, now Patent No. 3,128,539, dated Apr. 14, 1964. Divided and this application May 23, 1963, Ser. No. 282,608

4 Claims. (Cl. 72-348) This invention relates to the manufacture of wheels formed from cold deformable metal. More particularly, the invention is concerned with forming dies used in the manufacture of wheels.

This application is a division of our co-pending application, Ser. No. 82,748, filed January 16, 1961, for Wheel Manufacture, now Patent No. 3,128,539.

In the parent application a method is provided for making a flanged wheel from cold deformable metal wherein a portion of the metal is folded over upon itself in making the rim portion and in which all of the operations are accomplished by compression forces applied to the blank in an axial direction. The method is particularly adapted for manufacturing a wheel having a relatively deep annularly grooved flange formed integrally with the disk portion, in which method a sheet metal blank is first drawn into substantially cup shape, then a camming force is applied axially to the flanged portion of the cup to bulge it outwardly, and a compression force is then applied to the bulged portion in an axial direction to fold a part of the rim over upon itself. More specifically, in that method a cup shaped member is first drawn from a flat sheet metal blank so that an offset is formed in the flange portion of the cup and this offset portion is then bulged outwardly to form a bulge and the bulged portion is then folded over upon itself, all of these operations being accomplished by pressures applied in an axial direction so that the manufacture may be accomplished in a press,

It is an object of the present invention to provide an apparatus particularly adapted for use in carrying out such a method.

It is a further object of this invention to provide a set of economically produced cooperating forming dies for use in the manufacture of a wheel having an integral substantially V-shaped peripheral groove by the application of forces parallel to the axis of the wheel.

It is a further object of this invention to provide such cooperating forming dies for use in conventional press operations and involving only rigid die components, whereby such wheels can be manufactured economically in high volume production by means of die components having a long service life.

It is a further object of the invention to provide cooperating forming dies for such manufacture, said dies including a punch and outer die elements with a cooperating offset portion therebetween for forming, by relative axial movement, a cup shaped blank having an offset portion along its length, additional punch and cooperating outer die elements including an offset carnming portion on the punch for engaging, upon relative axial movement, the offset in said blank to cam it outwardly into a bulged configuration within clearance provided therefor, and further cooperating die means to overlap said bulge on itself to form one side of a V-shaped peripheral groove the other side of which is provided by a flaring peripheral portion of said blank.

Other objects and advantages of the invention will be apparent from the following description, the appended claims and the accompanying drawings, in which:

FIGURE 1 is a sectional view taken axially through a half of a partially formed blank and showing a first set of the forming dies at the end of the first drawing operation,

FIGURE 2 is a corresponding view showing a second part of the forming dies in a second operation on the 'blank,

FIGURE 3 is a corresponding view showing the position of the dies with the second operation only partially accomplished,

FIGURE 4 is the corresponding view showing trimming dies and the partially formed blank,

FIGURE 5 is a corresponding view showing the dies of a succeeding operation,

FIGURE 6 is an enlarged sectional view at the beginning of the camming operation illustrated in FIG- URE 3,

FIGURE 7 is an enlarged view showing the change accomplished by the operation of FIGURE 8,

FIGURE 8 is a sectional view showing the dies and wheel at the completion of a fifth operation,

FIGURE 9 is a sectional view showing the dies of a sixth operation,

FIGURE 10 is a corresponding sectional view showing the dies of a seventh operation, and

7 FIGURE 11 is a central sectional view of the completed wheel.

Referring more particularly to the drawings in which the cooperating dies of the present invention are illustrated, 10 designates a sheet metal blank at the completion of a first drawing operation performed in a suitable drawing press in which the several forming dies are operably mounted. These dies include a punch 11, surrounding which is a blank holding ring 12 and a drawing ring 13, and above which is the central portion 14 of the upper die. The die portion 14- is preferably a stripper slide. The punch 11 and the other dies shown are relatively moveable but in the particular form of die arrangement illustrated, the punch 11 is fixed. The blank holding ring 12 is supported by pins 15 on a pressure cushion, not shown, and the dies 13 and 14 are arranged on the upper slide of the press to be moved downwardly into the position shown and draw a flat disk of sheet metal into a substantially cup shaped form, as illustrated. This cup shaped form has a central disk portion 17, a generally cylindrical flanged portion 18 having a terminal outwardly flaring portion 19 with an offset 20 in the flanged portion about rnidway thereof. This offset portion is provided by offset or bulge 21 on the punch 11.

The second set of dies for performing the second operation, illustrated in FIGURE 2, include a punch 25 preferably fixed in the bed of a press and surrounded by a pressure pad 26 held on pines 27' operated by a suitable pressure cushion in the bed of the press. The pressure pad 26 has a recess 27 that receives the outwardly flanged portion 19 of the blank and this flanged portion is held firmly in place by radially moveable blank holding die sections, one of which is shown at 28. There may be several of these operable inwardly into the position shown in FIGURE 2 by the press mechanism after the partially formed blank has been placed on the pressure pad 26 with the pressure pad and the die sections 28 in an elevated position about level with the top of the punch. The upper die 30 is mounted on the press slide or ram and is provided with a recess 31 shaped to fit the top of the partially formed blanks, as produced by the die shown in FIGURE 1. However, there is a space 32 extending around the upper portion of the punch, as will be evident. The outer portion of the upper die 30 extends down to and cooperates with the pressure pad 26 and the die sections 28 and forces them downwardly against the action of the pressure pins so as to force the partially formed blank down over the punch into the position shown in FIGURE 2. Part way through the 3 stroke of the dies illustrated in FIGURE 2, the parts assume the instantaneous positions as shown in FIG- URE 3. In this position, it will be noted that a bulge near the upper end of the punch is just starting to engage the offset in the blank.

The main body portion of the punch has a diameter which is substantially the same as the maximum diameter of the lower cylindrical portion of the partially formed blank. The upper end of the punch, however, is smaller in diameter and is illustrated on a larger scale in FIGURE 6. It will be noted from FIGURE 6 that there is an inclined camming surface 34 that connects the main body portion to the upper portion of the punch which is of smaller diameter, the length of this camming portion in the direction of the axis of the blank being about the same as the distance from the camming surface to the end of the punch so that before the blank is fully drawn down over the punch, the camming surface 34 pushes radially outwardly by a camming operation on the bend 35 in the blank and bulges the middle portions of the flange outwardly in a symmetrical manner all around the flange without disturbing the lower portion of the flange where it merges into the flaring terminal end of the blank. This camming operation is accomplished by the application of a force in an axial direction on the blank with the top of the blank and the flaring terminal portion of the blank both confined. This produces a symmetrical outward bulge on the blank and forms it into the shake shown in FIGURE 2, extending into the space 32 at the upper die which has previously been referred to. It will be noted that since the camming portion 34 on the punch is rather close to the upper end of the punch, the camming operation will progress axially along the blank as the blank is forced down over the punch, leaving the upper portion of the flange closely adjacent to the end of the punch bent outwardly.

Although the trimming may take place at a different stage during the manufacture of the wheel, the trimming dies are now described as illustrated in FIGURE 4 in which inner die member 37 is preferably fixed on the press and serves in cooperation with a gripping slide 38 to hold an outer portion of the terminal flange 19 during the descent of a trimming die 39 so that the trimmed portion 40 will be separated from the blank. The several dies as illustrated, with the exception of the inner die 37, may be moved by the ram of the press, suitable springs 41 being interposed between the die portions 42 and 43 so that the blank will be gripped between die members 37 and 43 while being trimmed.

The partially formed blank is then compressed axially to overlap the bulged portion of the flange over upon itself, producing a reverse fold which finally takes the shape illustrated in FIGURE 9. However, it is preferred that this compression take place in two stages. The first of these stages is shown in FIGURE 5. Here the punch 45 may be supported by pressure pins 46 and is surrounded by a lower spring-pressed outer die 47, the vertical movements of which are limited by stop means 48. Carried by the lower die 47 are radially operable blank holding die sections 49, operable in time with the press movements so they may be moved inwardly into the position shown and cooperate with the outer die member 47 and hold the flanged portion 19 of the blank. When these die sections 49 move inwardly, they and the die member 47 are in an elevated position about in line with the upper end of the punch 45 which at that time is also elevated. The upper die 50 connected to the press slide has a downward extension 51 that forces the die portions 47 and 49 downwardly, but before they do so, with the central disk portion held between the upper die 50 and the upper end of the punch 45, an axial pressure is exerted on the flange causing it to bulge outwardly still further into the position shown in FIGURE 5. In this position, the shape of the partially formed blank is indicated at 53 in solid lines in- FIGURE 7.

The dies of FIGURE 8 produce a further outward flaring to move the bulge portion further outwardly to the position indicated in dotted lines in FIGURE 7. In FIG- URE 8, the punch 56 is fixed, the lower pressure pad 57 is held by pressure pins and cushions, and the radially operable blank holding die portions 58 hold the outwardly flanged terminal portion of the blank during a further bulging of the flange portion produced by the form of the central recess 59 in the upper die 60 which here is shape-d so that it flares outwardly as indicated at 61. The upper portion of the punch is also flared outwardly to a greater extent than is the punch 45 as indicated at 62..

In FIGURE 9, the partially formed blank 19 is placed on a punch 64 held by pressure cushion pin 65 so that the outwardly flaring flange is mounted in the recess 66 in the outer die 67 which is arranged on suitable springs 68. A stop 69 limits the travel of this outer die 67. Radially operable blank holding die sections 70 engage the upper side of the flange. Then the upper die 71 operated by the press slide descends and applies an axial force on the disk portion of the blank so as to overlap the bulged portion upon itself and force the overlapped portions tightly together coining them against the upper end of the punch 64 which is now shaped to the exact shape to be finally imparted to the central position of the wheel.

A punching operation to cut out the central hub hole 73 and to simultaneously turn down the end 74 of the flange, is indicated in FIGURE 10. The hub itself 75 may then be connected as by welding to the central portion of the formed wheel.

As will be apparent, the cooperating forming dies of this invention may all be used in a press or press operations and in all applications the forces are applied in an axial direction. By arranging the bulge in the proper manner on the flange that is initially drawn and by camming the bulge outwardly and then following this with a squeezing or compression operation through the unique punch and die configurations disclosed herein, grooved wheels can be manufactured on a high volume production basis, especially if suitable transfer mechanism is provided to move the parts from one set of dies to the next set of dies and on through to completion. The walls of the wheel produced by the dies of this invention will be of uniform strength and balanced with adequate strength at the parts where this is required.

While the apparatus herein described constitutes preferred embodiments of the invention, it is to be understood that the invention is not limited to the precise form of apparatus and that changes may be made therein without departing from the scope of the invention which is defined in the appended claims.

What is claimed is:

1. A set of cooperating forming dies for use in the manufacture of a sheet metal wheel having a disk portion and an integral substantially V-shaped peripheral groove comprising, a punch having a cylindrical body portion terminating in a circular curved end portion of reduced diameter with a tapered camming surface between the body portion and the end portion, the axial length of the camming surface being approximately the same as the distance from the camming surface to the end of the end portion and the peripheral part of the end portion being rounded, and an outer die extending around the punch and having an annular blank holding recess, radially operative blank holding die sections cooperating with the outer die, and an opposing die opposing the punch and having a shallow central recess shaped in accordance with the punch end and adapted for engagement with the central portion of the blank to be formed and engageable with the outer die to move therewith.

2. A set of cooperating forming dies for use in the manufacture of a sheet metal wheel having a disk portion and an integral substantially V-shaped peripheral groove comprising, a punch having a cylindrical body portion terminating in a circular curved end portion of reduced diameter with a tapered camming surface between the body portion and the end portion, said camming surface being spaced inwardly along the length of said punch from the end thereof and the peripheral part of the end portion being rounded, and an outer die extending around the punch and having an annular blank holding recess, radially operative blank holding die sections cooperating with the outer die, and an opposing die opposing the punch and having a shallow central recess shaped in accordance with the punch end and adapted for engagement with the central portion of the blank to be for-med and engageable with the outer die to move therewith.

3. Cooperating forming dies for use in the manufacture of a sheet metal wheel having an integral substantially V-shaped peripheral groove comprising, a first die set 1ncluding a punch and cooperating outer die elements carried for relative axial movement for performing a drawing operation upon a sheet metal blank interposed there between, said punch being generally cylindrical in configuration and having an end portion and a body portion of larger diameter than said end portion pnoviding an annular offset portion therebetween, said outer die elements including die means closely conforming to the configuration of said punch and holding 'means for en gaging the peripheral portion of said blank extending beyond said punch, whereby upon relative axial movement of said punch and die elements said blank is formed into a substantially cup shaped blank with an offset portion along its length and a flaring peripheral portion, a second die set including a second punch and cooperating second outer die elements, said second outer die elements including second die means closely conforming with the outer end of said punch, having substantial annular spacing extending around the body of said punch and including second holding means for engaging said flaring peripheral portion, said second punch being of generally cylindrical configuration and having a tapered camming surface between its end portion and a relatively larger body portion, said camming surface being spaced substantially closer to the outer end of said second punch than the relative spacing between said offset portion and the outer end of its respective punch whereby upon relative axial movement of said second punch and its associated die elements the camming surface of said second punch engages and cams the offset portion of said substantially cup shaped blank outwardly creating an annular bulge along the length of said blank between the flaring peripheral portion and inner end portion thereof within the clearance provided by said substantial annular spacing, and further cooperating die means carried for relative axial movement including cooperating punch and die elements for axially compressing said blank to overlap said bulge upon itself to thus form one side of said peripheral groove, the other side of which is provided by the flaring peripheral portion of said blank.

4. Cooperating forming dies for use in the manufacture of a sheet metal wheel having an integral substantially V-shaped peripheral groove comprising, a first die set including a punch and cooperating outer die elements mounted for relative axial movement for performing a drawing operation upon a sheet metal blank interposed therebetween, said punch being generally cylindrical in configuration and having an end portion and a body portion of larger diameter than said end portion providing an annular offset portion therebetween, said outer die elements including die means closely conforming to the configuration of said punch and holding means for engaging the peripheral portion of said blank extending beyond said punch, whereby upon relative axial movement of said punch and die elements said work element is formed into a substantially cup shaped blank with an offset portion along its length and a flaring peripheral portion, a second die set including a second punch and cooperating second outer die elements, said second punch having a cylindrical body portion terminating in a circular curved end portion of reduced diameter with a tapered camming surface between the body portion and the end portion, the axial length of the camming surface being approximately the same as the distance from the camming surface to the end of the end portion and the peripheral part of the end portion being rounded, said second outer die elements including an outer die extending around the punch having an annular blank holding recess, radially operative blank holding die sections cooperating with said outer die, and an opposing die opposing the punch having a shallow central recess shaped in accordance with the punch end for engagement with a central portion of the blank to be formed and with said outer die to move therewith, said distance from the camming surface to the end of the end portion of said second punch being substantially less than the distance from said offset portion to the outer end of its respective punch whereby upon relative axial movement of said second punch and its associated die elements the camming surface of said second punch engages and cams the offset portion of said substantially cup shaped blank outwardly creating an annular bulge along the length of said blank between the flaring peripheral portion and inner end portion thereof within the clearance provided by said substantial annular spacing, and further cooperating die means carried for relative axial movement including cooperating punch and outer die elements for axially compressing said blank to overlap said bulge upon itself to thus form one side of said peripheral groove, the other side of which is provided by the flaring peripheral portion of said blank.

References Cited by the Examiner UNITED STATES PATENTS 2,163,003 6/1939 Lyon 113-116 2,493,053 1/1950 Zatyko 113-116 CHARLES W. LANHAM, Primary Examiner. R. J. HERBST, Assistant Examiner. 

1. A SET OF COOPERATING FORMING DIES FOR USE IN THE MANUFACTURE OF A SHEET METAL WHEEL HAVING A DISK PORTION AND AN INTEGRAL SUBSTANTIALLY V-SHAPED PERIPHERAL GROOVE COMPRISING, A PUNCH HAVING A CYLINDRICAL BODY PORTION TERMINATING IN A CIRCULAR CURVED END PORTION OF REDUCED DIAMETER WITH A TAPERED CAMMING SURFACE BETWEEN THE BODY PORTION AND THE END PORTION, THE AXIAL LENGTH OF THE CAMMING SURFACE BEING APPROXIMATELY THE SAME AS THE DISTANCE FROM THE CAMMING SURFACE TO THE END OF THE END PORTION AND THE PERIPHERAL PART OF THE END PORTION BEING ROUNDED, AND AN OUTER DIE EXTENDING AROUND THE PUNCH AND HAVING AN ANNULAR BLANK HOLDING RECESS, RADIALLY OPERATIVE BLANK HOLDING DIE SECTIONS COOPERATING WITH THE OUTER DIE, AND AN OPPOSING DIE OPPOSING THE PUNCH AND HAVING A SHALLOW CENTRAL RECESS SHAPED IN ACCORDANCE WITH THE PUNCH END AND ADAPTED FOR ENGAGEMENT WITH THE CENTRAL PORTION OF THE BLANK TO BE FORMED AND ENGAGEABLE WITH THE OUTER DIE TO MOVE THEREWITH. 